CN112533890A - Process for producing methanol - Google Patents

Process for producing methanol Download PDF

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CN112533890A
CN112533890A CN201980052428.1A CN201980052428A CN112533890A CN 112533890 A CN112533890 A CN 112533890A CN 201980052428 A CN201980052428 A CN 201980052428A CN 112533890 A CN112533890 A CN 112533890A
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carbon dioxide
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methanol
methane
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CN112533890B (en
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斯里坎特·瓦桑特·巴德甘迪
巴拉苏布拉马尼扬·赛斯拉曼
维诺德·桑卡兰·奈尔
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Saudi Basic Global Technology Co ltd
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    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
    • C07C29/15—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
    • C07C29/151—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases
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    • C01B3/24—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by decomposition of gaseous or liquid organic compounds of hydrocarbons
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    • C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
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    • C01B2203/061—Methanol production
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    • C01B2203/08—Methods of heating or cooling
    • C01B2203/0805—Methods of heating the process for making hydrogen or synthesis gas
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    • C01B2203/0811—Methods of heating the process for making hydrogen or synthesis gas by combustion of fuel
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Abstract

A process for producing methanol is disclosed. The process comprises providing an oxidant of high oxygen content to combust hydrocarbons, particularly methane, and then using the resulting hot gas to heat natural gas to convert the natural gas to synthesis gas. The synthesis gas is used to produce methanol in a methanol synthesis reactor. At least some of the carbon dioxide from the hot gas is fed to a methanol synthesis reactor to produce methanol.

Description

Process for producing methanol
Cross Reference to Related Applications
This application claims priority to U.S. provisional patent application serial No. 62/715,194, filed 2018, 8/6, the entire contents of which are incorporated herein by reference in their entirety.
Technical Field
The present invention generally relates to the production of methanol. More particularly, the invention relates to a method for heating a medium by including the use of carbon dioxide (CO) from the heating medium2) Methanol is produced as one of the feedstocks for methanol production, wherein the heating medium provides heat to the reforming process.
Background
One conventional method for producing methanol involves producing synthesis gas from methane, followed by the reaction of carbon monoxide (CO), hydrogen (H) in the presence of a catalyst2) And synthesis gas to produce methanol. The reaction equation for steam reforming of methane to form syngas and for the reaction of carbon monoxide and hydrogen to form methanol are shown below.
CH4+H2O→CO+3H2
CO+2H2→CH3OH.
Traditionally, methanol production plants utilize excess air in a reformer combustor to combust natural gas (fuel) to generate the energy required to steam reform the natural gas (feedstock) to form syngas. In steam reforming methane to produce synthesis gas, three moles of hydrogen are formed for each mole of carbon monoxide formed. However, only two moles of hydrogen are consumed for each mole of carbon monoxide that is consumed in the formation of methanol. Thus, steam reforming produces excess hydrogen. The excess hydrogen produced in the steam reforming process is used for methanol production by introducing carbon dioxide and reacting the introduced carbon dioxide with the excess hydrogen to produce methanol, as shown below.
CO2+3H2→CH3OH+H2O。
This method, which consumes excessive hydrogen, is expensive and increases the production cost of methanol due to the high price of introducing carbon dioxide.
In addition, the use of excess air to combust the fuel gas results in other significant inefficiencies. For example, currently, combustion using excess air in a reforming combustor results in a diluted carbon dioxide stream containing about 5 wt% CO280% by weight of N2And 15% by weight of O2. This diluted stream is difficult to further treat and is therefore discharged as flue gas. Also, the use of excess air in the reformer burner reduces the burner flame temperature, thereby increasing the natural gas demand as fuel for the reformer burner. In summary, the use of excess air in combusting natural gas fuel and introducing excess carbon dioxide to consume excess hydrogen makes the methanol production process expensive.
In view of the above-mentioned emission of carbon dioxide-containing flue gases, it should be noted that the emission of carbon dioxide from industrial plants is an environmental issue. Carbon dioxide is a greenhouse gas that is continuously emitted into the earth's atmosphere primarily as a result of the burning of fossil fuels. Over the past few decades, there has been increasing global interest in the anthropogenic carbon dioxide emissions into the atmosphere.
Disclosure of Invention
The present inventors have found a more efficient and environmentally friendly process for the production of methanol from synthesis gas. The process involves the formation of carbon dioxide in situ which can then be used as an additional feedstock for the production of methanol and/or other valuable chemicals, such as urea. The method includes providing an oxidant, either pure oxygen or having a high concentration of oxygen, for combusting a fuel in a combustor of a reformer that produces syngas. The oxidant may be produced from air by an Air Separation Unit (ASU). The oxidant is used to completely or nearly completely combust the fuel in the combustor, thereby reducing fuel consumption and increasing syngas production in the reformer (e.g., steam reformer). The excess carbon dioxide produced using the high oxygen content oxidant is used as one of the feedstocks for the production of methanol and urea. The nitrogen from the air separation unit and any unreacted hydrogen from the reformer may be used to produce materials such as ammonia and urea. The method can obviously optimize the methanol equipment and improve the economic benefit. For example, although carbon dioxide is used in the process, the carbon dioxide is not introduced into the methanol production process. Instead, the method includes generating pure carbon dioxide (or nearly pure carbon dioxide) in situ from the combustor flue gas. In this way, carbon dioxide, which is normally vented to the atmosphere, can be used to form valuable products, such as methanol and urea.
Embodiments of the invention include a method of producing methanol. The process comprises combusting a feed hydrocarbon with an oxidant comprising 70 to 99.5 wt.% oxygen to generate heat and produce a heated gas stream having a temperature of 1200 to 1800 ℃. The heated gas stream comprises carbon dioxide and water. The method also includes heating the natural gas to a temperature sufficient to reform the natural gas and produce syngas using heat from the heated gas stream. The heating of the natural gas simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide and water. The method further includes reacting the syngas with at least some carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce methanol.
Embodiments of the invention include a method of producing methanol that involves separating a methane stream into a first methane stream and a second methane stream, and flowing the first methane stream into a combustor. The process further includes separating air in an air separation unit to produce an oxidant comprising 70 to 99.5 wt.% oxygen, 1 to 30 wt.% carbon dioxide (mixed to serve as a temperature modifier), and 0.1 to 5 wt.% nitrogen, along with trace impurities. The method further includes flowing an oxidant into the combustor and combusting the first methane stream with the oxidant and carbon dioxide produced by combustion of natural gas (which is used to control flame temperature) to generate heat and produce a heated gas stream having a temperature of from 1200 to 1800 ℃. The heated gas stream comprises carbon dioxide and water (in the form of steam). The method further includes contacting the heated gas stream with a reformer and flowing a second methane stream into the reformer. The method also includes heating the second methane stream with heat from the heated gas stream to a temperature sufficient to reform the second methane stream and produce syngas. The heating of the second methane stream simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide. The method further includes flowing the syngas into a methanol synthesis reactor, flowing at least some carbon dioxide in the cooled gas stream into the methanol synthesis reactor, and reacting the syngas and at least some carbon dioxide in the cooled gas stream in the methanol synthesis reactor at reaction conditions sufficient to produce methanol.
The following includes definitions for various terms and phrases used throughout the specification.
The term "about" or "approximately" is defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, these terms are defined as being within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.
The terms "weight%", "volume%" or "mole%" refer to the weight, volume, or mole percent of the component, respectively, based on the total weight, volume, or total moles of materials comprising the component. In a non-limiting example, 10mol of the component in 100mol of the material is 10 mol% of the component.
The term "substantially" and variations thereof are defined as ranges that include within 10%, within 5%, within 1%, or within 0.5%.
The terms "inhibit" or "reduce" or "prevent" or "avoid" or any variation of these terms, when used in the claims and/or specification, includes any measurable amount of reduction or complete inhibition to achieve a desired result.
The term "effective" as used in the specification and/or claims means sufficient to achieve a desired, expected, or intended result.
The use of the words "a" or "an" when used in the claims or the specification in conjunction with the terms "comprising," including, "" containing, "or" having "can mean" one, "but it also has the meaning of" one or more, "" at least one, "and" one or more than one.
The words "comprising" (and any form of comprising, such as "comprises" and "comprises"), "having" (and any form of having, such as "has" and "has"), "including" (and any form of including, such as "includes" and "includes") or "containing" (and any form of containing, such as "contains" and "contains") are inclusive or open-ended and do not exclude additional, unrecited elements or process steps.
The methods of the present invention can "comprise," "consist essentially of," or "consist of" the particular ingredients, components, compositions, etc. disclosed throughout the specification.
The term "predominantly", as that term is used in the specification and/or claims, means greater than any one of 50 weight percent, 50 mole percent, and 50 volume percent. For example, "predominantly" can include 50.1% to 100% by weight and all values and ranges therebetween, 50.1% to 100% by mole and all values and ranges therebetween, or 50.1% to 100% by volume and all values and ranges therebetween.
Other objects, features and advantages of the present invention will become apparent from the following drawings, detailed description and examples. It should be understood, however, that the drawings, detailed description, and examples, while indicating specific embodiments of the present invention, are given by way of illustration only, and not by way of limitation. In addition, it is contemplated that changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. In other embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiments. In further embodiments, additional features may be added to the specific embodiments described herein.
Drawings
For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a system for producing methanol according to an embodiment of the present invention;
FIG. 2 is a process for producing methanol according to an embodiment of the present invention; and
fig. 3 shows a graph of the results of a simulated methanol production process according to an embodiment of the invention.
Detailed Description
A process has been found for the production of methanol from synthesis gas. The process involves the in situ production of carbon dioxide which can then be used as an additional feedstock for the production of methanol and/or other valuable chemicals such as urea. The method includes providing an oxidant, either pure oxygen or having a high concentration of oxygen, for combusting a fuel in a combustor of a reformer that produces syngas. The oxidant may be produced from air by an Air Separation Unit (ASU). The oxidant is used to completely or almost completely burn the fuel in the combustor, thereby reducing fuel consumption and increasing syngas production in the reformer. By using such high oxygen content oxidant to combust the fuel, the flue gas of the combustor will contain excess carbon dioxide and water. Carbon dioxide can be easily separated from water and then used as a feedstock along with hydrogen to produce valuable products, such as methanol. In this way, the excess hydrogen is consumed by reaction with carbon dioxide to form methanol.
The method according to an embodiment of the invention can be used to optimize a methanol plant by using an air separation unit to obtain pure or nearly pure oxygen as oxidant that can be used to completely combust the fuel natural gas in the combustor to produce carbon dioxide and water. Most of the carbon dioxide in the combustor flue gas can be recovered by separating the water using a compression and condensation process. The purified carbon dioxide can then be used internally in a methanol reformer to consume excess hydrogen produced in the natural gas steam reforming process.
Embodiments of the present invention address the possibility of integrating a methanol production process with an ammonia and urea production process because nitrogen is produced as a byproduct in an air separation unit, excess carbon dioxide is available from the combustor flue gas (mixed to serve as a temperature modifier), and excess hydrogen is available from natural gas steam reforming.
As described above, conventional methanol plants utilize excess air in the reformer combustor to combust the fuel gas to generate the energy required for steam reforming (which results in significant energy inefficiencies) and introduce pure carbon dioxide to consume the excess hydrogen produced in the reforming section. The introduction of carbon dioxide makes conventional processes economically unattractive.
Fig. 1 shows a system 10 for producing methanol according to an embodiment of the present invention. Fig. 2 shows a process 20 for producing methanol according to an embodiment of the present invention. Method 20 may be implemented using system 10.
A method 20 implemented using the system 10 may involve flowing a natural gas feed stream 108 into a natural gas separator 107 that separates the natural gas feed stream 108 into a natural gas fuel stream 106 and a natural gas feed stream 109 in block 200. In this way, methane in natural gas serves as both a fuel and a feedstock. Natural gas comprises predominantly methane, and in embodiments of the invention, natural gas comprises 70 to 100 wt% methane, 0 to 30 wt% ethane, 0 to 10 wt% nitrogen, and 0 to 10 wt% propane, on a dry weight basis.
In an embodiment of the invention, the method 20 includes flowing a natural gas fuel stream 106 into the combustor 104 for combustion at block 201. Meanwhile, according to an embodiment of the present invention, at block 202, air stream 100 is separated by air separation unit 101 into oxidant stream 102 and nitrogen stream 103. According to an embodiment of the invention, oxidant stream 102 comprises 70 to 99.5 wt.% oxygen, 1 to 30 wt.% carbon dioxide (mixed to act as a temperature modifier), and 0.1 to 5 wt.% nitrogen, along with trace impurities; nitrogen stream 103 comprises 70 to 90 weight percent nitrogen and 10 to 30 weight percent oxygen. Because of CO2Has a high radiation absorption coefficient, so it can act as a temperature diffuser in the vicinity of a flame burning natural gas. Also, CO2Is an inert component in an oxygen rich environment that, due to its sensible heat, helps absorb some of the exothermic energy of combustion in the flame region. Thus, the CO may be optimized based on the desired flame temperature2Mixing the components.
At block 203, the oxidant stream 102 having a high oxygen content flows into the combustor 104. According to an embodiment of the invention, at block 204, the combustor 104 combusts the natural gas fuel 106 with the oxidant stream 102. Due to the high oxygen content of the oxidant stream 102, the natural gas fuel stream 106 may be completely or nearly completely combusted. According to an embodiment of the invention, the combustion at block 204 results in at least 95% to 100% of the hydrocarbons fed to the combustor 104 being oxidized. In this way, in the reformer 110 (e.g., a steam reforming unit), consumption of natural gas (fuel) is reduced, and generation of syngas is increased.
In an embodiment of the invention, at block 204, the carbon dioxide stream 105 is provided to the combustor 104 while the methane of the natural gas fuel stream 106 is combusted with the oxygen of the oxidant stream 102 in the combustor 104. In this manner, the carbon dioxide stream 105, as an inert gas under the conditions present in the combustor 104, can be used to control the flame temperature in the combustor 104. In embodiments of the invention, the flame temperature is in the range of 1500 to 3000 ℃ and all ranges and values therebetween, including the range of 1300 to 1350 ℃, 1350 to 1400 ℃, 1400 to 1450 ℃, 1450 to 1500 ℃, 1500 to 1550 ℃, 1550 to 1600 ℃, 1600 to 1650 ℃, 1650 to 1700 ℃, 1700 to 1750 ℃, 1750 to 1800 ℃, 1800 to 1850 ℃, 1850 to 1900 ℃, 1900 to 1950 ℃, 1950 to 2000 ℃, 2000 to 2050 ℃, 2050 to 2100 ℃, 2100 to 2150 ℃, 2150 to 2200 ℃, 2200 to 2250 ℃, 2250 to 2300 ℃, 2300 to 2350 ℃, 2350 to 2400 ℃, 2400 to 2450 ℃, 2450 to 2500 ℃, 2500 to 2550 ℃, 2550 to 2600 ℃, 2600 to 2650 ℃, 2650 to 2700 ℃, 2700 to 2750 ℃, 2750 to 2800 ℃, 2800 to 2850 ℃, 2850 to 2900 ℃, 2900 to 2950 ℃ and/or 2950 to 3000 ℃.
At block 204, combustion in the combustor 104 generates a heat load flow 112A (heated airflow). In embodiments of the invention, the heat load stream 112A may be heated to temperatures of 1200 to 1800 ℃ and all ranges and values therebetween, including ranges of 1200 to 1250 ℃, 1250 to 1300 ℃, 1300 to 1350 ℃, 1350 to 1400 ℃, 1400 to 1450 ℃ to 1500 ℃, 1500 to 1550 ℃, 1550 to 1600 ℃, 1600 to 1650 ℃, 1650 to 1700 ℃, 1700 to 1750 ℃ and/or 1750 to 1800 ℃. In an embodiment of the invention, block 205 shows the heat load stream 112A being directed to the reformer 110.
In an embodiment of the invention, the natural gas feed stream 109 also flows into the reformer 110 at block 206. At block 207, heat generated by combusting the natural gas fuel stream 106 and present in the heat load stream 112A is transferred to the natural gas feed stream 109 to generate a temperature sufficient to convert methane of the natural gas feed stream 109 to carbon monoxide and hydrogen in the syngas 111. In an embodiment of the invention, at block 207, the reaction conditions in the reformer 110 include a temperature in the range of 800 to 900 ℃ and all ranges and values therebetween, including ranges of 800 to 810 ℃, 810 to 820 ℃, 820 to 830 ℃, 830 to 840 ℃, 840 to 850 ℃, 850 to 860 ℃, 860 to 870 ℃, 870 to 880 ℃, 880 to 890 ℃, and/or 890 to 900 ℃. In an embodiment of the invention, at block 207, the reaction conditions in the reformer 110 include a pressure in the range of 10 to 20 bar and all ranges and values therebetween, including the range of 10 to 11 bar, 11 to 12 bar, 12 to 13 bar, 13 to 14 bar, 14 to 15 bar, 15 to 16 bar, 16 to 17 bar, 17 to 18 bar, 18 to 19 bar, and/or 19 to 20 bar. In an embodiment of the invention, the reaction at block 207 is carried out in the presence of a catalyst selected from the following list: nickel, alumina, calcium oxide, and combinations thereof. At the reformer 110, the natural gas feed stream 109 is converted to syngas 111. The syngas 111 includes carbon monoxide and hydrogen. In an embodiment of the invention, the syngas 111 comprises 15 to 25 wt.% carbon monoxide, 10 to 20 wt.% carbon dioxide, 5 to 15 wt.% hydrogen, and 40 to 50 wt.% water.
According to an embodiment of the invention, the transfer of heat from the heat load stream 112A to the natural gas feed stream 109 to produce syngas 111 cools the heat load stream 112A into flue gas 112B, which includes primarily carbon dioxide and water. In an embodiment of the invention, flue gas 112B comprises 70 to 80 wt.% carbon dioxide and 20 to 30 wt.% water.
Carbon dioxide and water of flue gas 112B can be easily separated. For example, in an embodiment of the invention, at block 208, the method 20 involves a separation unit 113 that separates the flue gas 112B into a stream comprising primarily water (water stream 114) and a stream comprising primarily carbon dioxide (carbon dioxide stream 115).
In an embodiment of the invention, the carbon dioxide separator 116 separates the carbon dioxide stream 115 into a carbon dioxide feed stream 118 and an excess carbon dioxide stream 117 at block 209. In embodiments of the invention, the excess carbon dioxide stream 117 is fed to the combustor 104 as carbon dioxide stream 105 as an aspect of block 204 and/or the excess carbon dioxide stream 117 is injected into the reformer 110. The excess carbon dioxide stream 117 acts as a diluent as an inert gas when supplied to the combustor 104 and thus can be used to control the flame temperature of the natural gas fuel stream 106 burning in the combustor 104.
According to an embodiment of the invention, at block 210, syngas stream 111 is channeled to cooling and separation unit 119 wherein syngas stream 111 is cooled and separated into first syngas stream 120 and second syngas stream 121. In an embodiment of the invention, the first syngas stream 120 and the second syngas stream 121 comprise 30 to 40 wt.% carbon dioxide, 40 to 50 wt.% carbon monoxide, 10 to 20 wt.% hydrogen, and 0 to 10 wt.% water, respectively. The first synthesis gas stream 120 may be separated in a Pressure Swing Absorption (PSA) unit 124 to form a hydrogen stream 123 comprising primarily hydrogen and a carbon oxide stream 125 comprising primarily carbon dioxide and carbon monoxide.
According to an embodiment of the invention, at block 211, the second syngas stream 121 is directed to the methanol synthesis reactor 126. In an embodiment of the invention, the carbon dioxide feed stream 118 is directed to the methanol synthesis reactor 126 at block 212.
According to an embodiment of the invention, the second syngas stream 121 and the carbon dioxide feed stream 118 are reacted and converted to methanol in the methanol synthesis reactor 126 at block 213. In an embodiment of the invention, the reaction conditions provided for block 213-synthesis of methanol from carbon monoxide, carbon dioxide and hydrogen-in the methanol synthesis reactor 126 include temperatures in the range of 225 to 275 ℃ and all ranges and values therebetween, including ranges of 225 to 230 ℃, 230 to 235 ℃, 235 to 240 ℃, 240 to 245 ℃, 245 to 250 ℃, 250 to 255 ℃, 255 to 260 ℃, 260 to 265 ℃, 265 to 270 ℃ and/or 270 to 275 ℃. In an embodiment of the invention, the reaction conditions in the methanol synthesis reactor 126 for synthesizing methanol at block 213 include pressures in the range of 80 to 100 bar and all ranges and values therebetween, including ranges of 80 to 82 bar, 82 to 84 bar, 84 to 86 bar, 86 to 88 bar, 88 to 90 bar, 90 to 92 bar, 92 to 94 bar, 94 to 96 bar, 96 to 98 bar, and/or 98 to 100 bar. In an embodiment of the invention, the methanol synthesis reaction is carried out in the presence of a catalyst selected from the following list, at block 213: copper, zinc oxide, aluminum oxide, and combinations thereof.
The methanol produced at block 213 is discharged into the reactor effluent 128. In an embodiment of the invention, the reactor effluent 128 comprises 30 to 40 wt% methanol, 10 to 20 wt% carbon dioxide, 0 to 5 wt% carbon monoxide, 10 to 20 wt% hydrogen, and 10 to 20 wt% water. According to an embodiment of the invention, at block 214, the reactor effluent 128 is sent to a cooling and separation unit 129. In an embodiment of the invention, at block 215, the cooling and separation unit 129 separates the reactor effluent 128 into an intermediate product stream 131 and a recycle stream 130. As shown in block 216, recycle stream 130, comprising primarily carbon dioxide and hydrogen, may be recycled to methanol synthesis reactor 126 as recycle syngas 127 and/or to combustor 104 for combustion as purge gas 135.
In an embodiment of the invention, at block 217, the depressurization and separation unit 132 reduces the pressure of the intermediate product stream 131 and separates the intermediate product stream 131 into a vent gas stream 133 and a crude methanol stream 134.
In embodiments of the invention, (1) at least a portion of the excess carbon dioxide stream 117 may be integrated with an ammonia/urea plant for the production of urea and/or (2) the hydrogen stream 123 and nitrogen stream 103 may be integrated with an ammonia/urea plant to produce ammonia. More specifically, nitrogen from nitrogen stream 103 can react with hydrogen from hydrogen stream 123 or other hydrogen source to form ammonia. The ammonia formed may then be reacted with carbon dioxide in a portion of the excess carbon dioxide stream 117 to form urea.
Embodiments of the present invention as described herein can significantly optimize a methanol production plant and result in increased economic benefit by using carbon dioxide to produce additional methanol, where the carbon dioxide is produced in situ within the reformer combustor.
Embodiments of the invention described herein may have the following benefits: (a) reduced fuel natural gas consumption in the reformer burner due to combustion using pure oxygen or an oxidant with a high concentration of oxygen; (b) the in situ production of pure or nearly pure carbon dioxide consumes excess hydrogen produced in the reformer to produce additional methanol, (c) the increased use of natural gas as a feedstock to generate additional synthesis gas, resulting in additional methanol production per unit of natural gas.
Although embodiments of the present invention have been described with reference to the blocks of fig. 2, it should be understood that the operations of the present invention are not limited to the specific blocks and/or the specific order of the blocks shown in fig. 2. Accordingly, embodiments of the invention may use various blocks in a different order than that of FIG. 2 to provide the functionality as described herein.
Examples
The following includes specific examples as part of the disclosure of the invention. The examples are for illustrative purposes only and are not intended to limit the invention. One of ordinary skill in the art will readily recognize parameters that may be varied or modified to produce substantially the same results.
Simulation of methanol production process
This example relates to the first cutting model in the Aspen Plus software (as shown in figure 1) that was constructed for the utilization of carbon dioxide in a methanol plant that resulted in the production of additional methanol from excess hydrogen in the synthesis gas stream entering the methanol synthesis reactor according to the following reaction scheme:
CO+2H2＝CH3OH
CO2+3H2＝CH3OH+H2O
CO2+H2＝CO+H2O。
assumptions in the simulations include: (a) the total amount of natural gas is fixed: 2788 kmol/hr or 415.1kta, (b) split of natural gas is different for injected carbon dioxide, thus achieving energy balance between reformer and burner, (c) reforming and methanol synthesis are assumed to be operating at equilibrium in this study, (d) all calculations are relative to the base case of zero carbon dioxide injection, (e) net benefit is defined on a monetary basis (incremental methanol-make-up water-natural gas equivalent steam)/ton of methanol relative to the base case without injected carbon dioxide.
Based on the simulation, the results reflected in the graph shown in fig. 3 were obtained. Figure 3 shows that as the carbon dioxide feed to the methanol synthesis reactor increases, the methanol produced per hour increases. Thus, there is a clear economic reason to inject carbon dioxide into a methanol synthesis reactor to generate additional methanol from excess hydrogen that would otherwise be lost as a purge stream and ultimately used as fuel in a reformer.
A preliminary comparison of the proposed concept with a conventional methanol production process is shown below:
Figure BDA0002936079800000111
based on the above table, the injection of pure oxygen has a considerable advantage in terms of natural gas savings compared to conventional reformers for methanol production.
In the context of the present invention, at least the following 19 embodiments are described. Embodiment 1 is a process for producing methanol. The process comprises combusting a feed hydrocarbon with an oxidant comprising 70 to 99.5 wt.% oxygen to generate heat and produce a heated gas stream having a temperature of 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water. The method further includes heating the natural gas to a temperature sufficient to reform the natural gas and produce syngas using heat from the heated gas stream, wherein the heating of the natural gas simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide and water. The method further includes reacting the syngas with at least some carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce methanol. Embodiment 2 is the method of embodiment 1, further comprising separating air in an air separation unit to produce the oxidant. Embodiment 3 is the method of any one of embodiments 1 or 2, wherein the air separation unit comprises a list selected from the group consisting of: cryogenic distillation units, pressure swing adsorption/membrane separation units, and combinations thereof. Embodiment 4 is the method of embodiment 3, further comprising producing ammonia and/or urea using a feedstock comprising nitrogen from an air separation unit. Embodiment 5 is the method of any one of embodiments 1 to 4, further comprising separating carbon dioxide from water in the cooled gas stream and using the separated carbon dioxide for reaction with the syngas. Embodiment 6 is the method of any one of embodiments 1 to 5, further comprising separating the methane stream into a first methane stream and a second methane stream, and flowing the first methane stream to the combustor, wherein the first methane stream comprises a feed hydrocarbon combusted with an oxidant. Embodiment 7 is the method of embodiment 6, further comprising flowing the heated gas stream into a reformer and flowing a second methane stream into the reformer, wherein the second methane stream comprises heated natural gas. Embodiment 8 is the method of any one of embodiments 1 to 7, wherein the oxidant further comprises 1 to 30 weight percent carbon dioxide (mixed to act as a temperature regulator) and 0.1 to 5 weight percent nitrogen. Embodiment 9 is the method of any one of embodiments 1 to 8, wherein the combusting oxidizes from 95 to 100 weight percent of the feed hydrocarbon. Embodiment 10 is the method of any one of embodiments 1 to 9, wherein the cooled gas stream comprises 55 to 65 wt.% carbon dioxide, 35 to 45 wt.% water, and 0.1 to 3 wt.% nitrogen. Embodiment 11 is the method of any one of embodiments 1 to 10, wherein a portion of the carbon dioxide from the cooled gas stream is used in an ammonia and/or urea production process. Embodiment 12 is the method of any one of embodiments 1 to 11, wherein a portion of the carbon dioxide from the cooled gas stream is used as a diluent in the combustion of the feed hydrocarbon. Embodiment 13 is the method of embodiment 12, wherein the flow of carbon dioxide from the cooled gas stream to the combustion of the feed hydrocarbon is varied to control the flame temperature of the combustion. Embodiment 14 is the method of embodiment 13, wherein the flame temperature of the combustion is in the range of 1500 to 3000 ℃. Embodiment 14 is the method of any one of embodiments 1 to 13, wherein the conversion of natural gas to methanol is in the range of 70% to 95%. Embodiment 16 is the method of any one of embodiments 1 to 15, wherein the reforming of the natural gas comprises reacting the natural gas with water.
Embodiment 17 is a method of producing methanol. The process includes combusting a first methane stream methane with an oxidant comprising 70 to 99.5 wt.% oxygen to generate heat and produce a heated gas stream having a temperature of 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water. The method also includes heating the second methane stream with heat from the heated gas stream to a temperature sufficient to reform the second methane stream and produce syngas, wherein the heating of the second methane stream simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide and water. The method further includes reacting the syngas with at least some carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce methanol.
Embodiment 18 is a method of producing methanol. The process includes separating a methane stream into a first methane stream and a second methane stream, and flowing the first methane stream into a combustor. The method also includes separating air in an air separation unit to produce an oxidant comprising 70 to 99.5 wt.% oxygen, 1 to 30 wt.% carbon dioxide, and 0.1 to 5 wt.% nitrogen and flowing the oxidant into a combustor. The method further includes combusting the first methane stream with an oxidant to generate heat and produce a heated gas stream having a temperature of from 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water. Additionally, the method includes flowing the heated gas stream into a reformer and flowing a second methane stream into the reformer. The method further includes heating the second methane stream with heat from the heated gas stream to a temperature sufficient to reform the second methane stream and produce a syngas, wherein the heating of the second methane stream simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide, and passing the syngas to a methanol synthesis reactor. The method also includes flowing at least some carbon dioxide in the cooled gas stream into a methanol synthesis reactor and reacting the syngas and at least some carbon dioxide in the cooled gas stream in the methanol synthesis reactor at reaction conditions sufficient to produce methanol. Embodiment 19 is the method of embodiment 18, wherein carbon dioxide produced from combustion of natural gas is sent to a reaction zone where a first methane stream is combusted.
Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure set forth above, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims (18)

1. A method of producing methanol, the method comprising:
combusting a feed hydrocarbon with an oxidant comprising 70 to 99.5 wt.% oxygen to generate heat and produce a heated gas stream having a temperature of 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water;
heating the natural gas to a temperature sufficient to reform the natural gas and produce syngas using heat from the heated gas stream, wherein the heating of the natural gas simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide and water; and
the synthesis gas is reacted with at least some carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce methanol.
2. The method of claim 1, further comprising: air is separated in an air separation unit to produce an oxidant.
3. The method of any one of claims 1 and 2, wherein the air separation unit comprises a list selected from the group consisting of: cryogenic distillation units, pressure swing adsorption/membrane separation units, and combinations thereof.
4. The method of claim 3, further comprising: ammonia and/or urea is produced using a feed comprising nitrogen from an air separation unit.
5. The method of any of claims 1 to 4, further comprising: the water in the cooled gas stream is separated from the carbon dioxide and the separated carbon dioxide is used in the step of reacting the synthesis gas.
6. The method of any of claims 1 to 5, further comprising: separating the methane stream into a first methane stream and a second methane stream; and
flowing a first methane stream into a combustor, wherein the first methane stream comprises a feed hydrocarbon combusted with an oxidant.
7. The method of claim 6, further comprising:
flowing the heated gas stream into a reformer; and
flowing a second methane stream into the reformer, wherein the second methane stream comprises heated natural gas.
8. The method of any one of claims 1 to 7, wherein the oxidant further comprises 1 to 30 wt.% carbon dioxide and 0.1 to 5 wt.% nitrogen.
9. The process of any one of claims 1 to 8, wherein the combusting oxidizes from 95 to 100 wt.% of the feed hydrocarbons.
10. The method of any one of claims 1 to 9, wherein the cooled gas stream comprises 55 to 65 wt.% carbon dioxide, 35 to 45 wt.% water, 0.1 to 3 wt.% nitrogen.
11. A method according to any one of claims 1 to 10, wherein a portion of the carbon dioxide from the cooled gas stream is used in an ammonia and/or urea production process.
12. A method according to any one of claims 1 to 11, wherein a portion of the carbon dioxide from the cooled gas stream is used as a diluent in the combustion of the feed hydrocarbon.
13. The method of claim 12, wherein the flow of carbon dioxide from the cooled gas stream to the combustion of the feed hydrocarbon is varied to control the flame temperature of the combustion.
14. The method of claim 13, wherein the temperature of the burning flame is in the range of 1500 to 3000 ℃.
15. The process of any one of claims 1 to 13, wherein the conversion of natural gas to methanol is in the range of from 70% to 95%.
16. The method of any one of claims 1 to 15, wherein reforming of the natural gas comprises reacting the natural gas with water.
17. A method of producing methanol, the method comprising:
combusting the first methane stream with an oxidant comprising 70 to 99.5 wt.% oxygen to generate heat and produce a heated gas stream having a temperature of 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water;
heating the second methane stream with heat from the heated gas stream to a temperature sufficient to reform the second methane stream and produce syngas, wherein the heating of the second methane stream simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide and water; and
the synthesis gas is reacted with at least some carbon dioxide from the cooled gas stream under reaction conditions sufficient to produce methanol.
18. A method of producing methanol, the method comprising:
separating the methane stream into a first methane stream and a second methane stream;
flowing the first methane stream into a combustor;
separating air in an air separation unit to produce an oxidant comprising 70 to 99.5 wt.% oxygen, 1 to 30 wt.% carbon dioxide, and 0.1 to 5 wt.% nitrogen;
flowing the oxidant into a combustor;
combusting the first methane stream with an oxidant to generate heat and produce a heated gas stream having a temperature of from 1200 to 1800 ℃, wherein the heated gas stream comprises carbon dioxide and water;
flowing the heated gas stream into a reformer;
flowing a second methane stream into a reformer;
heating the second methane stream with heat from the heated gas stream to a temperature sufficient to reform the second methane stream and produce syngas, wherein the heating of the second methane stream simultaneously cools the heated gas stream to form a cooled gas stream comprising carbon dioxide;
flowing the synthesis gas into a methanol synthesis reactor;
flowing at least some of the carbon dioxide in the cooled gas stream into a methanol synthesis reactor; and
at least some of the carbon dioxide in the syngas and the cooled gas stream is reacted in the methanol synthesis reactor under reaction conditions sufficient to produce methanol.
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